Composition of a weatherable roofing composite product

Abstract

A novel composition of weatherable and semi-weatherable materials that can be injection molded or extruded into sheets or rolls to create a roofing product wherein the roofing product overlaps in order to provide a substantially weatherable covering on a roof. The roofing product has a top layer (14) made of weatherable polymers and multiple substrate layers (22, 30) made of semi-weatherable polymers. A decorative, three dimensional appearing layer (16) of colorants is uniquely applied to the bottom surface (15) of the top layer (14). The weatherable top layer (14) is preferably an ASA or acrylic-type copolymer. The semi-weatherable bottom layers (22, 30) are specialized formulations of fire resistant polymers, where the semi-weatherable bottom layers (22, 30) have had the Heat Deflection Temperature (HDT) uniquely improved for use in roofing. The product has multi-layering UV stability. The multiple layers can be injection molded or extruded or laminated or preferably multi-layer-extruded, thus bonded. Then the bonded materials maybe used directly as a finished roofing product (10) or thermoformed product (10a) (if not injection molded) to resemble more popular types of roof coverings such as shake or shingles or slate or tiles or geometric and natural patterns. The multiple layers are engineered to pass stringent roofing building codes such as the International Construction Code (ICC), including fire rating

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This Application is a continuation of and claims priority from PCT Application Serial No. PCT / US05 / 43443, filed Nov. 30, 2005.BACKGROUND OF THE INVENTION[0002](1) Field of the Invention[0003]This invention pertains to roofing materials. More specifically, the invention concerns a novel composition of materials to create lightweight, decorative, weatherable multi-layer polymeric roofing system to meet specific building code requirements set by the International Code Council (ICC).[0004](2) Description of the Related Art[0005]This specific roofing product patent application is a continuing improvement of the inventor's previous patent U.S. Pat. No. 6,536,177. A patent search before and after issuance of the inventor's previous patent U.S. Pat. No. 6,536,177 does not indicate any of the present invention's improvements. Further U.S. Pat. No. 6,536,177 was shown to be differentiated from the closest prior art of U.S. Pat. No. 5,306,548 issued...

AI Technical Summary

Benefits of technology

[0034]Acrylonitrile / Styrene / Acrylate polymer (ASA) as being specially formulated to have high tensile strength, elongation at break, modulus of elasticity in tension, impact strength, Vicat softening temperature and density. It is an impact modified, weatherable, copolymer with high thermal stability, good chemical resistance, and resistance to weathering, aging, and yellowing.

Problems solved by technology

Tiles are quite durable; however, their disadvantage is that they require a substantial amount of labor in their installation and can break on impact.

Tiles tend to be excessively heavy and dangerous in earthquakes and high winds, and will fall through the roof in the event of a fire.

Tiles are also expensive to ship because they are so heavy.

Wood shakes and shingles are also subject to breakage as well as rot and loss of coloration.

Their cost is high and they are labor intensive to install.

Furthermore, wood shakes and shingles can be relatively heavy, are flammable, porous and cannot withstand relatively high wind velocity.

The inherent disadvantages of tiles and shakes have led to the development of alternative roofing materials such as plastics.

However, many of the plastics have disadvantages, which typically may include poor ability to insulate, poor ability to withstand the ultra violet (UV) radiation from the sun, and poor ability to withstand shock from an impact (such as from people walking on the roof or hail).

Plastics tend to become brittle, deformed and break with age.

Also, plastics tend to loose color over time.

Because of these disadvantages, the majority of roofing materials are made of asphalt shingles.

However, the natural materials are still in high demand because the asphalt shingles are unattractive and simply utilitarian in appearance.

This bonding method is not applicable for a roofing application because of the extreme weathering conditions and subsequent failure by delaminating of layers or adhesive chemical incompatibilities with materials including colorants.

This method will not hold up to the extreme weathering of a roof, where the protective coating peels, discolors, wears from blowing dirt and, most importantly, deteriorates the printed materials.

Chemical pollution results from chemicals contained in smog and other air pollutants.

These chemicals contribute to color loss, brittleness and other factors that decrease the durability of many types of roofing materials.

Furthermore the prior art is silent as to the ability of their compositions' ability to pass stringent building codes.

Zabrocki's formulations (U.S. Pat. Nos. 5,306,548 or 5,334,450) do not meet plastic roofing building code requirements.

There are a limited number of materials that provide a clear weatherable film such as polycarbonate, polymethyl methacrylate (PMMA) and acrylic plastic.

The drawback for the use of such materials for roofing is decorative coloration, cost and durability.

However, in a weatherable roofing application decorative designs by coloration to resemble the intricate features of roofing materials such as shake, slate or tile have never been seen before.

Also, coloration has been unsuccessful in meeting the long term performance of roofing or the weatherable demands placed on the materials such as chemical compatibility, UV protection of the colorants and materials used.

Another problem with most coloration processes is that it is applied to the exterior of a surface to gain control over the design.

This method is impractical in a roofing application because chemicals, pollutants, wind, sand and other forms of weather will wear the colorants off the surface in a short time.

Still another problem is that if one is to encapsulate a decorative faux design between two solid layers, then the design would be covered from view by the top layer.

Using a clear material invites UV degradation which would be fatal for a full sun roofing material.

Further, colorants are mostly very flammable and not applicable for a fire rated roofing application.

This interlayer adhesive bonding method is not applicable for a roofing application because of the extreme weathering conditions and subsequent failure by delaminating of layers or adhesive chemical incompatibilities with materials including colorants.

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